Method for manufacturing a building block

ABSTRACT

A method for manufacturing a building element with at least two reference surfaces that are spaced apart and have a predetermined position relative to each other. The method includes forming at least two part-elements, with each part-element being formed of a hardened molding mass such that a first of the part-elements defines a first of the reference surfaces and a second of the part-elements defines a second of the reference surfaces. The two part-elements are positioned against each other with a resiliently deformable tie layer therebetween so that the first and second references surfaces face away from each other and the predetermined position thereof is established, after which the tie layer is hardened.

The present invention relates to a method for manufacturing a building element provided with at least one reference plane which is equally smooth and accurately sized, whereby a matrix with the shape of the desired building element is filled with a hardenable moulding mass through an opening in one of the matrix walls.

Building blocks are generally known. Generally, they have the form of a rectangular parallelepiped, wherein the top and bottom surfaces are used as stack surfaces and the lateral surfaces as finishing surfaces. Deviating forms are used as well, more particularly, for special structures such as curves, fronts or corner blocks.

In conventional building systems, the building block finishing is usually not critical because deviations can be easily compensated for by the tie layer used between the building blocks. Thereby, the use of cheap materials, such as clay, chalky sandstone, and concrete for manufacturing building blocks is indeed possible.

In other building systems, such as disclosed for example in the European Patent Application no 98922689.9, the connection between two building blocks is such that the size deviations can no longer be compensated for by an intermediate layer. This applies more particularly to the top and bottom surfaces, but could also apply in special applications for other surfaces.

However, it is desired to use also in such systems building blocks from “cheaper” materials. The materials, however, show always upon hardening expansion or shrinkage phenomena which influence the shape accuracy and/or flatness of the external surfaces, but also the mutual position of the external surfaces, more particularly the distance between the upper and lower surfaces and the parallelism thereof. Compensating for those defects would require a costly and intricate operation reducing the effect of the cheap material.

An object of the invention is to provide a method for manufacturing a building block of the above-mentioned type, whereby the mentioned disadvantages would be overcome.

Such an object is reached according to the invention so that, after filling the filling opening or another opening in a matrix wall, a pressure is exerted on the moulding mass, so that the moulding mass matches well the matrix walls and optional gas-forming components may escape through micro-openings in the matrix walls, whereupon the moulding mass can be hardened in such a condition.

Manufacturing a part-block can occur technically simply so that a surface of such a part-block has the appropriate shape accuracy and/or flatness, while the shrinkage or expansion phenomena occurring upon hardening can no longer happen in the other limiting surfaces. The tie layer being subsequently applied can be selected so that the shrinkage or expansion phenomena have no influence on the position of the reference surfaces.

Moreover, this method makes it possible to achieve complex shapes, which cannot be obtained with conventional forming techniques.

Additionally, it is possible to combine various materials in one building block, for example, by making each part-block from different layers with each their own material.

Other features and advantages of the invention will become apparent from the following description in which the appended drawings are referred to, wherein:

FIG. 1 is a schematic cross-sectional illustration of the various steps for manufacturing a block according to the invention,

FIG. 2 is a schematic cross-section of a block with reinforcing and securing projections,

FIG. 3 is a schematic illustration of a part-block during the manufacture thereof,

FIG. 4 is a schematic illustration of the method according to the invention for manufacturing a block with the appropriate size,

FIG. 5 is a schematic illustration of the method according to the invention for manufacturing a part-block with parallel surfaces and with a correct height size, and

FIG. 6 is a schematic illustration of the method according to the invention for connecting two block parts together with a thin glue layer so that the height is correct.

FIG. 1 schematically represents a method for moulding a block made of two part-blocks 1 and 2. Thereby the two part-blocks are manufactured in moulds 3 and 4 with a smooth bottom 5 and 6, for example by casting concrete and hardening it, whereupon the two part-blocks are adhered to one another with glue or cement 7, so that the smooth lower sides 8 and 9 now form the lower and upper surfaces of the block. Shrinkage or expansion resulting from the hardening of the layer 7 can now hardly occur because of the very limited thickness of the layer 7.

FIG. 2 shows schematically an additional reinforcement 10 illustrated in the tie layer 7, with a portion 11 thereof projecting out of the block for creating the opportunity to secure or to hang something thereto. The holes for the connecting bolts, as disclosed in the European Patent Application no 98922689.9 are represented in full scale in FIG. 1, but are only represented with a dashed line in FIG. 2.

FIG. 3 shows schematically a part-block 12 where on a smooth bottom 13 of a mould 14 a trough 15 is placed whereon or wherein the concrete 16 is being cast. Such a trough 15 can be made of a metal or a synthetic material so that a block is produced from two part-blocks with a lower side and a top side made of a synthetic material or a metal so that, in the case where two blocks would slightly slide from each other as a result of wind pressure, temperature differences, vibrations due to the traffic or earthquakes, no crumbling of the concrete would result. With the same system, after the part-blocks are hardened, a resilient coating can be formed on the block lower and upper surfaces, but this coating might not adhere after drying.

FIG. 4 shows schematically a method for connecting two part-blocks 17 and 18 together, wherein the height and the parallelism of the block lower and upper surfaces 19 and 20 have exactly the desired extent. Thereby, the lowest block part 17 with its smooth upper surface 19 is laid onto a surface 21—or on at least three points forming a surface—whereupon a glue or cement layer 22 is applied onto the block part 17 so as to apply the uppermost block part 18 on it in a non hardened state in the correct position, whereby the block is now higher than the desired size so that now with a second surface 23—or at least three points forming a surface—which is parallel to the lower surface 21, the two block parts 17 and 18 are forcibly (24) pressed towards each other, so that a block with the correct height is generated where use can optionally be made of spacers 25 with the required desired length.

In the case where the tie layer, in a plastic condition between the two component stones 17 and 18, has such an unsatisfactory rigidity in itself to keep the part-blocks at least at the required distance from each other, harder elements can be added into the tie layer, such as clay fragments, lead balls or the like which are distorted during assembly so that the correct distance is held.

After producing the highly accurate blocks, these can be linked to one another by means of bolts or coupling bars, so that an accurate structure is generated wherein, without any adjustments, prefabricated window and door frames, stairs, kitchens and sanitary facilities can be installed, leading to a quicker finishing of the structure. As the block is produced very accurately, beside concrete, very high quality concrete, foamed glass, foamed aluminium and various composite materials can be used as materials since the relatively thin glue or cement layer can compensate for high pressures.

FIG. 5 shows schematically a method for manufacturing a part-block 25 with smooth upper and lower sides 26 and 27 by means of casting the concrete in a mould 28 with the correct height which is clamped between two smooth plates 29 and 30 and wherein mould filling may occur, for example, through an opening 34 in 30 through which air may escape out of the mould through some small slots 32 in the upper edge of the mould 28.

FIG. 6 shows schematically that two part-blocks 25 and 33 with four smooth upper surfaces 26, 27, 34 and 35 are glued to each other, wherein the glue layer can be very thin, resulting in the surfaces 26 and 34 being smooth, so that the parts 25 and 33 are arranged between two flat plates 36 and 37, which, when being forcibly pressed (38), are held parallel and give the block an appropriate heigth, where use can optionally be made of spacers 29 with the required appropriate length.

Obviously, the invention is not restricted to the disclosed and illustrated embodiments, i.e. a block with two parallel surfaces. Within the scope of the invention, other block shapes can however be made with two reference surfaces, such as for example, curve-shaped blocks, corner blocks and the like. Moreover, the invention is not rectricted to the disclosed materials, but any generally used materials can be used. More particularly, it is possible as well to manufacture blocks based on elements made of different layers and/or parts, each made of another material.

Moreover it is possible to use the process according to the invention in such a way that the outer surface of the building elements is made of a durable material, as described before, whereas the inner space is filled with a lighter material, such as polystyrene foam or the like. 

1. A method for manufacturing a building element with at least two reference surfaces that are spaced apart and have a predetermined position relative to each other, the method comprising the steps of: forming at least two part-elements, each part-element being formed of a hardened molding mass such that a first of the part-elements defines a first of the reference surfaces and a second of the part-elements defines a second of the reference surfaces; positioning the two part-elements against each other with a resiliently deformable tie layer therebetween so that the first and second references surfaces face away from each other and the predetermined position thereof is established; and then hardening the tie layer. 2-6. (canceled)
 7. A method according to claim 1, further comprising the step of placing a reinforcement in the tie layer, wherein the reinforcement defines a securing means extending from the building element after the hardening step.
 8. A method according to claim 1, wherein the part-elements have through-holes aligned as a resulting of the position step, the method further comprising inserting means in the through-holes for mechanically securing the part-elements to each other.
 9. A method according to claim 1, further comprising the step of coating at least one of the reference surfaces with a synthetic material or a metal foil.
 10. A method according to claim 1, further comprising the step of providing at least one of the reference surfaces with a non sticky resilient coating.
 11. A method according to claim 1, wherein each of the reference surfaces is flat.
 12. A method according to claim 1, wherein the reference surfaces are parallel to each other after the positioning step.
 13. A method according to claim 1, wherein the part-elements are formed of concrete, foamed glass, foamed aluminium or a composite material.
 14. A method according to claim 1, wherein the tie layer is formed of glue, cement, or a synthetic material.
 15. (canceled) 